Process for the preparation of wide pore catalysts

Abstract

This invention relates to alumina and/or silica supported catalysts which have a portion of their pores in the range of 75-1500 Å and wherein are or more catalytically active metal species is contained substantially within said pores. Carbon black particles having pores of 75-1500 Å and which have been reacted with the catalyst metal are used to prepare the catalyst using alumina and/or silica gels.

We claim: 
     
       1. A process of preparing a catalyst composition which comprises: (a) reacting carbon black with one or more catalytically active metal species,   (b) initially slurrying the reacted carbon black particles with an alumina- and/or silica-containing gel,   (c) drying the product of step (b),   (d) calcining the product of step (c) at an elevated temperature sufficient to convert the gel to an oxide, and   (e) burning out the carbon black in an oxygen-containing atmosphere.   
     
     
       2. The process of claim 1 wherein the carbon black particles have diameters ranging from about 75 to about 1500 Å. 
     
     
       3. The process of claim 2 wherein the diameters range from about 100 to about 1000 Å. 
     
     
       4. The process of claim 3 wherein the diameters range from about 100 to about 600 Å. 
     
     
       5. The process of claim 1 wherein step (a) comprises contacting the carbon black particles with a solution of one or more catalytically active metal salt(s), compound(s) and/or complex(es) dissolved in a solvent, drying the resultant metal-containing carbon black particles to remove the solvent and heating the carbon black particles to decompose the metal salt(s), compound(s) or complex(es). 
     
     
       6. The process of claim 1 wherein step (a) comprises contacting the carbon black particles with a solution of one or more catalytically active metal salt(s), compound(s) and/or complex(es) dissolved in a solvent and drying the resultant carbon black particles whereby dried metal salt(s), compound(s), and/or complex(es) deposit out on the carbon black particles. 
     
     
       7. The process of claim 1 wherein step (a) comprises contacting the carbon black particles with a solution of one or more catalytically active metal salt(s), compound(s) and/or complex(es) dissolved in a solvent, adding a precipitating agent to precipitate the metal salt(s), compound(s) and/or complex(es), and drying the resultant metal-containing carbon black particles to remove the solution solvent. 
     
     
       8. The process of claim 1 wherein step (b) comprises slurrying the carbon black with the gel in the presence of an aqueous slurrying medium. 
     
     
       9. The process of claims 1, 2, 3, 4, 5, 6, 7 or 8 wherein steps (c), (d) and (e) are combined in one step in an oxygen-containing atmosphere at a maximum temperature of ranging up to about 700° C. 
     
     
       10. The process of claims 1, 2, 3, 4, 5, 6, 7 or 8 wherein step (d) and (e) are combined in one step in an oxygen-containing atmosphere at a temperature ranging up to about 700° C.